Battery cover for a high voltage automotive battery

ABSTRACT

A cover for a battery module having a plurality of battery cells arranged in a stacked configuration includes a non-conductive main body having a plurality of spaced apart recessed regions formed therein and a plurality of electrically conductive connectors, each of the connectors disposed in one of the recessed regions and coupled to the main body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 13/045,964, filed on Mar. 11, 2011. The entire disclosure of theabove application is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to a battery module. Inparticular, the invention is directed to a battery cover for a batterymodule including a plurality of the battery cells.

BACKGROUND OF THE INVENTION

A battery cell has been proposed as a clean, efficient andenvironmentally responsible power source for electric vehicles andvarious other applications. One type of battery cell is known as thelithium-ion battery. The lithium-ion battery is rechargeable and can beformed into a wide variety of shapes and sizes so as to efficiently fillavailable space in electric vehicles. A plurality of individuallithium-ion battery cells can be provided in a battery cell module toprovide an amount of power sufficient to operate electric vehicles.

For example, a conventional battery module includes a plurality ofbattery cells arranged in a stacked configuration and in electricalcommunication with an electrical device (e.g. battery disconnect unit(BDU) or load). Each of the battery cells includes a cathode terminaland an anode terminal. Typically, the anode terminal and cathodeterminal of each of the battery cells are electrically connected in aseries configuration in order to maximize the voltage output of thebattery module. In certain designs, a battery cover is disposed over thestack of the battery cells to isolate and protect the anode and cathodeterminals of each of the battery cells.

It would be desirable to develop a cover for a battery module includinga plurality of battery cells arranged in a stacked configuration,wherein the cover optimizes a mechanical and electrical connectionbetween the battery cells while minimizing complexity.

SUMMARY OF THE INVENTION

Concordant and consistent with the present invention, a cover for abattery module including a plurality of battery cells arranged in astacked configuration, wherein the cover optimizes a mechanical andelectrical connection between the battery cells while minimizingcomplexity, has surprisingly been discovered.

In one embodiment, a cover for a battery module having a plurality ofbattery cells arranged in a stacked configuration comprises: anon-conductive main body having a plurality of spaced apart recessedregions formed therein; and a plurality of electrically conductiveconnectors, each of the connectors disposed in one of the recessedregions and coupled to the main body.

In another embodiment, a battery module comprises: a plurality ofbattery cells arranged in a stacked configuration, each of the batterycells including a first terminal having a positive electrical charge anda second terminal having a negative electrical charge disposed adjacenta first end thereof, a cover having a main body with a plurality ofspaced apart recessed regions formed therein; and a plurality ofelectrically conductive connectors, each of the connectors disposed inone of the recessed regions formed in the main body of the cover, eachof the connectors abutting at least one of the first terminal and thesecond terminal of at least one of the battery cells, wherein the firstterminal of the at least one of the battery cells is in directelectrical communication with the second terminal of an adjacent one ofthe battery cells through one of the connectors.

The present invention also includes methods of manufacturing a batterymodule.

One method includes the steps of: arranging a plurality of battery cellsin a stacked configuration, each of the battery cells including a firstterminal having a positive electrical charge and a second terminalhaving a negative electrical charge disposed adjacent a first endthereof, disposing a cover adjacent the first terminal and the secondterminal of each of the battery cells, the cover having a main body witha plurality of spaced apart recessed regions formed therein and each ofa plurality of electrically conductive connectors is disposed in one ofthe recessed regions, each of the connectors abutting at least one ofthe first terminal and the second terminal of at least one of thebattery cells; and passing an electromagnetic radiation through the mainbody of the cover to weld each of the connectors to the at least one ofthe first terminal and the second terminal of at least one of thebattery cells, wherein the first terminal of the at least one of thebattery cells is in direct electrical communication with the secondterminal of an adjacent one of the battery cells through one of theconnectors.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present invention, willbecome readily apparent to those skilled in the art from the followingdetailed description of the preferred embodiment when considered in thelight of the accompanying drawings in which:

FIG. 1 is a partially exploded front perspective view of a batterymodule including a battery cover according to an embodiment of thepresent invention;

FIG. 2 is a front perspective view of the battery module of FIG. 1showing the battery cover coupled to a plurality of battery cells of thebattery module;

FIG. 3 is a bottom perspective view of the battery cover of the batterymodule of FIGS. 1; and

FIG. 4 is schematic representation of the battery module of FIG. 1 inelectrical communication with a battery disconnect unit according to anembodiment of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The following detailed description and appended drawings describe andillustrate various embodiments of the invention. The description anddrawings serve to enable one skilled in the art to make and use theinvention, and are not intended to limit the scope of the invention inany manner. In respect of the methods disclosed, the steps presented areexemplary in nature, and thus, the order of the steps is not necessaryor critical.

FIGS. 1-2 illustrate a battery module 10 according to an embodiment ofthe present invention. As shown, the battery module 10 includes aplurality of battery cells 12 arranged in a stacked configuration and abattery cover 14 disposed adjacent the stack of battery cells 12. As anon-limiting example, the battery module 10 includes twelve of thebattery cells 12. However, any number of the battery cells 12 can beincluded to provide a pre-determined voltage.

Each of the battery cells 12 includes a pair of terminals 16, 18 (e.g.tabs). As a non-limiting example, the first terminal 16 (e.g. anode) isassociated with a negative electrical charge and the second terminal 18(e.g. cathode) is associated with a positive electrical charge. Incertain embodiments, the first terminal 16 of each of the battery cells12 is formed from copper, while the second terminal 18 of the each ofthe battery cells 12 is formed from aluminum. However, it is understoodthat each of the terminals 16, 18 can be formed from any conductivematerial.

In the embodiment shown, the first terminal 16 and the second terminal18 of each of the battery cells 12 are disposed on the same end of eachof the associated battery cells 12, as appreciated by one skilled in theart. In certain embodiments, each of the battery cells 12 is a prismaticbattery cell having a rectangular metal can (i.e. housing). However,other types of battery cells having other shapes and configurations canbe used. As a non-limiting example, the battery cells 12 are arranged inan alternating configuration, wherein the first terminal 16 of one ofthe battery cells 12 is aligned with the second terminal 18 of anadjacent one of the battery cells 12. However, other configurations canbe used.

In certain embodiments, a cooling plate 20 is disposed between adjacentones of the battery cells 12. It is understood that the cooling plates20 can be configured to pass a coolant therethrough. As a non-limitingexample, each of the cooling plates 20 forms part of a cooling circuitfor a liquid coolant system (not shown), as appreciated by one skilledin the art. However, other cooling systems and thermal managementsystems can be used.

As more clearly shown in FIG. 3, the battery cover 14 includes a mainbody 22 and a plurality of electrically conductive connectors 24 coupledto the main body 22. The main body 22 is typically formed (e.g. molded)from a non-conductive material (e.g. plastic, glass, or the like). As anon-limiting example, the main body 22 is substantially transparent,wherein an electromagnet radiation (e.g. laser) can pass therethrough.In the embodiment shown, the main body 22 has a substantiallyrectangular planar shape. However, the main body 22 can have any shapeand size. As a further non- limiting example, a plurality of spacedapart recessed regions 26 (i.e. cutouts) is formed on a lower side ofthe main body 22, while an upper side of the main body 22 issubstantially planar and flat. It is understood that any number of therecessed regions 26 can be formed in the main body 22.

The connectors 24 are typically coupled to the lower side of the mainbody 22 to abut each of the terminals 16, 18 of each of the batterycells 12, when the cover 14 is positioned on the stack of the batterycells 12. As a non-limiting example, each of the connectors 24 has asubstantially planar shape. However, the connectors 24 can have any sizeand shape. As a further non-limiting example, each of the connectors 24is disposed in one of the recessed regions 26 formed in the main body22. In certain embodiments, each of the connectors 24 is insert moldedwith the main body 22. However, the connectors 24 can be coupled to anyportion of the main body 22 using other means such as adhesives andother mechanical connections.

In the embodiment shown, each of the connectors 24 has a first portion28 formed from a first conductive material (e.g. copper) and a secondportion 30 formed from a second conductive material (e.g. aluminum). Asa non-limiting example, the first conductive material is different fromthe second conductive material. However, the connectors 24 can be formedfrom any electrically conductive material. As a non-limiting example,the first portion 28 of the at least one of the connectors 24 is coupledto the second portion 30 using an ultrasonic welding technique, adiffusion bonding, or another coupling technique now know or laterdeveloped. As a further non-limiting example, a strip of the firstconductive material is disposed adjacent a strip of the secondconductive material and the strips are coupled together using a couplingtechnique such as a continuous ultrasonic welding, for example. Thejoined strips are then cut to provide the connectors 24 having the firstportion 28 formed from the first conductive material and the secondportion 30 formed from the second conductive material. It is understoodthat other means of coupling the first portion 28 and the second portion30 can be used.

In the embodiment shown, each of a pair of end connectors 24′, similarto the connectors 24 except as described herein below, is disposedadjacent opposite ends of the main body 22 of the cover 14 andpositioned to extend beyond a peripheral edge of the main body 22. As anon-limiting example, one of the end connectors 24′ is electricallycoupled to the anode terminal 16 of one of the battery cells 12positioned at an end of the stack configuration, while the other of theend connectors 24′ is electrically coupled to the cathode terminal 18 ofone of the battery cells 12 positioned at another end of the stack.Accordingly, the end connectors 24′ collectively provide a positive andnegative end terminal for electrical circuit connection to anotherdevice 32 such as a load, a BDU, and another one of the battery modules10, for example (as shown in FIG. 4). As a further non-limiting example,each of the end connectors 24′ is generally “L” shaped and positioned inone of the recessed regions 26 formed in the main body 22. However, itis understood that the end connectors 24′ can have any shape and can bepositioned in any location relative to the cover 14.

To assemble the battery module 10, each of the battery cells 12 isdisposed adjacent another of the battery cells 12 having a differentorientation to form a stacked configuration. The terminals 16, 18 ofeach of the battery cells 12 are electrically coupled to each other in apre-determined sequence and electrical configuration (e.g. in series).Specifically, the cover 14 is positioned adjacent the terminals 16, 18of each of the battery cells 12, wherein the connectors 24, 24′ arealigned with the terminals 16, 18 of the battery cells 12. As anon-limiting example, the connectors 24 are arranged in a pre-determinedlayout so that the first portion 28 of each of the connectors 24 isdisposed adjacent the first terminal 16 of an associated one of thebattery cells 12 and the second portion 30 of each of the connectors 24is disposed adjacent the second terminal 18 of an associated one of thebattery cells 12. Additionally, one of the end connectors 24′ isdisposed adjacent the first terminal 16 of one of the battery cells 12disposed at an end of the stack, while the other of the end connectors24′ is disposed adjacent to the second terminal 18 of one of the batterycells 12 disposed at an opposite end of the stack. It is understood thatthe connectors 24, 24′ can be directly abutting respective ones of theterminals 16, 18.

Once the cover 14 is in position, the connectors 24, 24′ are coupled tothe respective terminals 16, 18 of the battery cells 12. In certainembodiments, an electromagnetic radiation (e.g. laser) is passed throughthe main body 22 of the cover 14 to weld the connectors 24, 24′ to therespective terminals 16, 18. However, other coupling means can be used.

As a non-limiting example, the first terminal 16 (e.g. anode) of atleast one of the battery cells 12 is in direct electrical communicationwith the second terminal 18 (e.g. cathode) of an adjacent one of thebattery cells 12. As a further non-limiting example, a direct electricalcommunication can be defined as a current flowing between the firstterminal 16 (e.g. anode) of the at least one of the battery cells 12 andthe second terminal 18 (e.g. cathode) of the adjacent one of the batterycells 12 without intervening electrical contact with another of thebattery cells 12. In certain embodiments, the end connectors 24′protrude from the main body 22 of the cover 14 to facilitate connectionof the battery module 10 to the device 32 or other system (as shown inFIG. 4). It is understood that electrically conductive bus bars (notshown) can be used to electrically couple the end connectors 24′ to thedevice 32. It is further understood that other means of providingelectrical communication between the battery module 10 and anotherdevice or system can be used.

Each of the battery cells 12 typically has two electrical connectionpoints (i.e. the terminals 16, 18), wherein one of the connection pointsis formed from a copper material and the other of the connection pointsis formed from an aluminum material. For effective joining together, thematerials of the electrical connection points should be joined with likematerial. In other words, copper should connect to copper and aluminumto aluminum. The battery module 10 including the cover 14 of the presentinvention facilitates the electrical connection of multiple batterycells with a single assembled apparatus (i.e. the cover 14 including theconnectors 24, 24′).

Since the conductive connectors 24, 24′are integrated with the main body22, the cover 14 of the present invention minimizes a profile of abattery connection apparatus and the overall profile of the batterymodule 10. The cover 14 includes an electrically insulative main body 22that provides a “touch safe” surface without requiring a distinct safetycover. The battery module 10 of the present invention optimizes amechanical and electrical connection between the battery cells 12 whileminimizing complexity and the overall number of required parts.

From the foregoing description, one ordinarily skilled in the art caneasily ascertain the essential characteristics of this invention and,without departing from the spirit and scope thereof, make variouschanges and modifications to the invention to adapt it to various usagesand conditions.

What is claimed is:
 1. A method of manufacturing a battery module, themethod comprising the steps of: arranging a plurality of battery cellsin a stacked configuration, each of the battery cells including a firstterminal having a positive electrical charge and a second terminalhaving a negative electrical charge disposed adjacent a first endthereof; disposing a cover adjacent the first terminal and the secondterminal of each of the battery cells, the cover having a main body witha plurality of spaced apart recessed regions formed therein and aplurality of electrically conductive connectors, wherein each of theconnectors is disposed in one of the recessed regions and abuts at leastone of the first terminal and the second terminal of at least one of thebattery cells; and passing electromagnetic radiation through the mainbody of the cover to weld each of the connectors to the at least one ofthe first terminal and the second terminal of at least one of thebattery cells, wherein the first terminal of the at least one of thebattery cells is in direct electrical communication with the secondterminal of an adjacent one of the battery cells through one of theconnectors.
 2. The method according to claim 1, wherein directelectrical communication between the battery cells is only establishedwith the cover in an installed position.
 3. The method according toclaim 1, wherein the first terminal on each of the battery cells isformed from a first conductive material and the second terminal on eachof the battery cells is formed from a second conductive materialdifferent from the first conductive material.
 4. The method according toclaim 3, wherein each of the connectors includes a first portion formedfrom the first conductive material and a second portion formed from thesecond conductive material.
 5. The method according to claim 4, whereinthe first terminal of each of the battery cells is coupled to the firstportion of one of the connectors and the second terminal of each of thebattery cells is coupled to the second portion of one of the connectors.6. The method according to claim 1, wherein the battery cells areconfigured in opposing orientation to align the first terminal of one ofthe battery cells with a second terminal of an adjacent one of thebattery cells.
 7. The method according to claim 1, wherein the main bodyis substantially transparent.
 8. The method according to claim 1,wherein at least one of the connectors has a substantially planar shapewith a first portion formed from a first conductive material and asecond portion formed from a second conductive material.
 9. The methodaccording to claim 8, wherein the first conductive material is differentfrom the second conductive material.
 10. The method according to claim1, wherein at least one of the connectors is substantially “L” shaped.11. The method according to claim 1, wherein at least one of theconnectors extends beyond a peripheral edge of the main body.
 12. Themethod according to claim 1, wherein the main body is non-conductive.13. A method of manufacturing a battery module, the method comprisingthe steps of: arranging a plurality of battery cells in a stackedconfiguration, each of the battery cells including a first terminalhaving a positive electrical charge and a second terminal having anegative electrical charge disposed adjacent a first end thereof,wherein the first terminal on each of the battery cells is formed from afirst conductive material and the second terminal on each of the batterycells is formed from a second conductive material different from thefirst conductive material; disposing a cover adjacent the first terminaland the second terminal of each of the battery cells, the cover having anon-conductive main body with a plurality of spaced apart recessedregions formed therein and a plurality of electrically conductiveconnectors, wherein each of the connectors is disposed in one of therecessed regions and abuts at least one of the first terminal and thesecond terminal of at least one of the battery cells; and passingelectromagnetic radiation through the main body of the cover to weldeach of the connectors to the at least one of the first terminal and thesecond terminal of at least one of the battery cells, wherein the firstterminal of the at least one of the battery cells is in directelectrical communication with the second terminal of an adjacent one ofthe battery cells through one of the connectors.
 14. The methodaccording to claim 13, wherein direct electrical communication betweenthe battery cells is only established with the cover in an installedposition.
 15. A method of manufacturing a battery module, the methodcomprising the steps of: arranging a plurality of battery cells in astacked configuration, each of the battery cells including a firstterminal having a positive electrical charge and a second terminalhaving a negative electrical charge disposed adjacent a first endthereof; disposing a cover adjacent the first terminal and the secondterminal of each of the battery cells, the cover having a non-conductiveand substantially transparent main body with a plurality of spaced apartrecessed regions formed therein and a plurality of electricallyconductive connectors, wherein each of the connectors is disposed in oneof the recessed regions and abuts at least one of the first terminal andthe second terminal of at least one of the battery cells; and passingelectromagnetic radiation through the main body of the cover to weldeach of the connectors to the at least one of the first terminal and thesecond terminal of at least one of the battery cells, wherein the firstterminal of the at least one of the battery cells is in directelectrical communication with the second terminal of an adjacent one ofthe battery cells through one of the connectors.
 16. The methodaccording to claim 15, wherein direct electrical communication betweenthe battery cells is only established with the cover in an installedposition.
 17. The method according to claim 15, wherein theelectromagnetic radiation comprises a laser.
 18. The method according toclaim 15, wherein the first terminal on each of the battery cells isformed from a first conductive material and the second terminal on eachof the battery cells is formed from a second conductive materialdifferent from the first conductive material.
 19. The method accordingto claim 18, wherein each of the connectors includes a first portionformed from the first conductive material and a second portion formedfrom the second conductive material.
 20. The method according to claim19, wherein the first terminal of each of the battery cells is coupledto the first portion of one of the connectors and the second terminal ofeach of the battery cells is coupled to the second portion of one of theconnectors.